AHEAD OF THE CURVEIN WELDING TECHNOLOGY

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FIREFLY – THE CLEVER WAY TO WELD!

FEATURES & BENEFITS

FIREFLY IS AN ADAPTABLE SYSTEM FOR WELDING, CUTTING AND BEVELLING AND IS FULL OF CLEVER FEATURES TO MAKE YOUR LIFE EASIER:

THE FIREFLY, COMMONLY REFERRED TO AS A ‘WELDING BUG’ OR ‘WELD HEAD’, IS A SEMI-AUTOMATIC WELDING MACHINE DESIGNED AND MANUFACTURED IN BELGIUM BY WELDING COMPANY.

The firefly’s unique features give you a clever welding machine

that will work with you in the most challenging environments.

The firefly is designed to meet the most rigorous standards and

is particularly suited to applications requiring a high level of

weld repeatability.

The main purpose of the firefly system is to improve the

productivity of the welder by continually producing a consistent

weld result.

We believe this gives our customers a competitive edge in

today’s ever demanding economic climate.

> Firefly incorporates leading digital

technology for precise control of key

welding parameters.

> Firefly has multiple pass welding capability

for workpieces in all gravity positions.

> Firefly has sector control. This feature

enables the customisation of specific

sectors to give the maximum flexibility and

repeatability to weld parameters.

> Firefly has an automatic torch height

adjustment feature as standard (with

suitable inverters).

> Firefly’s robust design features cope

with the most demanding applications

and terrain.

> Firefly systems are calibrated to enable all

weld procedures to perform exactly the

same when using multiple Firefly machines.

> Firefly has a root pass capability without the

need for copper or ceramic backing shoes.

> Firefly’s compact size means it can work in

confined areas.

> Firefly has both hard wire and flux core

welding capability due to the high torque

motor installed, effective feed of all types of

weld wire is possible.

> Firefly is compatible with suitable inverters

from all manufacturers.

> All this combines to give you a clever welding

machine that fulfils your automated welding

requirements

ALL THIS COMBINES TO GIVE YOU A CLEVER WELDING MACHINE

THAT FULFILS YOUR AUTOMATED WELDING REQUIREMENTS

.

INTEGRATED WELD DATA LOGGER

The firefly weld head has a simple band clamping latch

mechanism to enable fast and effective clamping of the weld

head to the band. Positioning the weld head on the workpiece

is straightforward by using a ‘free wheel’ setting before final

locking of the weld head into the chosen position.

Removing firefly from the band is equally simple with a latch

release mechanism. Mounting the guide band to the workpiece

is aided by a simple attach and release mechanism on the

guide band.

Firefly can operate on various band designs – orbital on an

external track or orbital on an internal track. Firefly also has

a linear capability; where it can operate on a flat track, both

vertical and horizontal.

For applications where the workpiece is neither round or linear,

but oval or curved instead, a specially modified Firefly is possible.

Firefly has a bi-directional capability on all band configurations –

there is no need for separate left and right hand machines.

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Firefly Max includes an integrated arc welding data logger and

monitoring unit.

Firefly Light is without data logger.

The unit offers a built in solution – a seamless integration with

minimal start up times and no external cabling.

Mounted to the front of the firefly Max control box, the eight-

inch touch screen unit will monitor variables such as arc

voltage, arc current, wire feed speed, travel speed, arc time

and traverse speed.

Data is captured digitally, direct from the weld power source.

PURPOSEThe purpose of the unit is to aid the decision making process by providing users with information about the actual weld.

> Real time weld monitoring – the unit measures the defined

variables to enable the comparison of those variables to

upper and lower limits within the weld procedure, then

communicates the results of this comparison.

> Weld data acquisition – the unit measures, displays and stores

the defined variables to evaluate specific arc characteristics.

> Production data – the unit provides various layers of

productivity related information.

The value of the unit comes when the output is compared to

the pre-set tolerances for the workpiece.

Armed with real time information, the user can quickly identify

potential process variances and take appropriate remedial

action to ensure the weld procedure is followed.

Firefly is a semi-automated machine – the welders must use their skill to make

final adjustments to the weld by operating the remote once the weld is underway.

With constant use throughout a welding shift, firefly’s operator’s remote is designed for ease of

handling and operation. Much attention has been given to the size, weight and physical robustness

of the unit. Similar attention has been given to the positioning and colour of the positive click buttons.

The remote incorporates leading digital technology to enhance response times.

A hi-visibility display screen enables ease of parameter identification and quality buttons offer long life

and reliability.

The remote is connected to firefly’s control box and controls functions such as

travel speed, travel direction and oscillation.

Each firefly remote is inter-changeable with all firefly

control boxes.

After extensive field testing, the ease of use design

features and physical robustness of the remote

will suit most users. However, other options

are available.

HMI PROGRAMMING LAPTOPFirefly uses a ruggedized laptop computer as a programming

pendant to enable welding parameter set-up in a familiar

windows environment – 50 parameter memories come as

standard. Each firefly HMI is compatible with all firefly control

boxes, so only one HMI is required per worksite.

The firefly HMI has a ‘team viewer’ remote assist capability.

This feature enables on-line diagnostics to be carried out by

technicians. Firefly’s HMI allows the user to download actual

weld programming data to a USB memory stick for further

processing in an Excel spreadsheet format.

TRAVEL BANDSFirefly is a ‘bug and band’ system – the bug or weld head runs on

a travel guide band (sometimes called a track or ring) which is

mounted to the workpiece.

With set-up times a key factor for most welding projects, much

attention has been given to aid this important process.

USING THE UNITThe unit is already fully integrated; there is no additional setting

up time.

The operator enters basic data about the weld – such as user ID,

weld number, welder position – then it’s good to go.

Just press ‘arc-on’ and the unit starts to record the weld data.

KEEPING UP WITH INFORMATION DEMANDSWeld records are a significant part of the huge amount of

documentation required to achieve weld validation.

The unit will allow the actual weld data to be exported directly to

a computer for compilation of weld records for the job –

there is no need to re-enter data manually from reams of

printed material.

If printed documentation is required for QA purposes, data can

be printed from automatically generated PDF reports.

OPERATOR’S REMOTE

SERVICES Rent or buy

The firefly welding system is available to rent

or buy.

If the duration of your welding project is a few

months, then renting firefly equipment may be

a good option to consider.

If you have longer term projects, or several

projects lined up, then buying the equipment

may be a better option.

To make a sales enquiry or to ask a question

about our rent or buy options, please contact us.

Welding services

We can provide firefly operators to support

your project.

This service includes welding crews,

supervisory staff, technicians and support staff.

We can also help with weld procedure

development for your project.

Training

Although the firefly system is intended

to be used by trained welders, a training

and familiarisation course is provided to

customers.

An experienced welder can be trained to use

firefly in one to two days.

Each course is tailored to the skill and

experience of the trainee and the intended

application.

The course in practical with an emphasis on

‘hands on’ use of firefly.

Ancillary equipment

The firefly welding system can be supplied with

ancillary equipment – integrated inverter sets,

induction heating equipment and automated cutting

equipment.

After sales support

The firefly welding system is supported by

Welding CompanyBrandekensweg 62627 Schelle (Antwerp) Belgium.

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oil, gas and water pipelines

large diameter vessel fabrication

tubular structures

power plant construction, nuclear and

conventional

pressure vessel construction

General fabrication

WELDING SOLUTIONS FOR INDUSTRY

FIREFLY CAN BE USED WHERE A HIGH DEGREE OF WELD REPEATABILITY IS REQUIRED AND A FLAT OR FLEXIBLE GUIDE BAND CAN BE MOUNTED TO THE WORKPIECE.

SPECIFICATIONS

Minimum Weld Diameter 6 inches (150mm)

Maximum Weld Diameter Unlimited

Maximum Wall Thickness Unlimited

Maximum Oscillation Width 3.6 inches (92mm) independently adjustable in 0.0001 inch (0.01 mm) increments

Dwell Time 0-8 independently adjustable in 0.01s increments

Travel Speed 0-270 inches (0-6858mm) per minute

Wire Capacity 0.8 – 2.0mm

Machine Weight10kg Wire off board model14kg Wire on board model (without 5kg spool)

Machine DimensionsLength 30cmWidth 17cmHeight 27cm to 33cm

wind and wave farm construction

chemical and petrochemical facility

construction

internal welds

steam pipes

shipyard construction work

FOR MORE INFORMATION ABOUT THE SUITABILITY OF FIREFLY FOR YOUR INTENDED APPLICATION, PLEASE CONTACT US.

> Spare parts

An extensive stock of spare parts is maintained

for rapid despatch to customers.

> Online technical support

Technicians have access to online remote assist

diagnostics software. This enables technicians to

resolve firefly technical issues anywhere in the

world.

> Software upgrades

Software upgrades can be downloaded and

installed from the customer log in area of the

manufacturer’s website.

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CONTACT US

Welding Company nv/sa

Brandekensweg 6

2627 Schelle

Belgium

Tel: +32 (0) 3 880 81 80

Email: jw@weldingcompany.be Website: www.weldingcompany.be